Knitting machine

ABSTRACT

A knitting machine designed to produce a continuous length of knitted fabric in a course-wise direction wherein knitting needles are mounted for reciprocating knitting movements in needle-carrying sections linked together to form a continuous oval unit. The needle-carrying sections are rotated relative to a plurality of threads and to preset cams which reciprocate the needles in knitting movements. A plurality of hooks are fixed for movement in a continuous oval path with a straight portion thereof extending adjacent a straight portion of the needlecarrying sections, with the hooks cammed to engage the knitted fabric as it comes from the needles to provide a wale-wise bias on the fabric as it is knitted.

United States Patent Muller May 16, 1972 [54] KNITTING MACHINE [72] Inventor: Rienk J. Muller, Minneapolis, Minn.

[73] Assignee: Munsingwear, Inc., Minneapolis, Minn. 22 Filed: Oct. 5, 1970 [21] Appl. No.: 77,869

FOREIGN PATENTS OR APPLlCATlONS 651,926 10/1937 Germany ..66/l

Primary Examiner-Ronald Feldbaum Attorney-Merchant & Gould 57 ABSTRACT A knitting machine designed to produce a continuous length of knitted fabric in a course-wise direction wherein knitting needles are mounted for reciprocating knitting movements in needle-carrying sections linked together to form a continuous oval unit. The needle-carrying sections are rotated relative to a plurality of threads and to preset cams which reciprocate the needles in knitting movements. A plurality of hooks are fixed for movement in a continuous oval path with a straight portion thereof extending adjacent a straight portion of the needlecarrying sections, with the hooks cammed to engage the knitted fabric as it comes from the needles to provide a walewise bias on the fabric as it is knitted.

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INVENTOR. J. MULLER R1 ENK M gsj z AT TORNE Ys P'ATENTEDM 16 I972 sum 10 HF 11 'I'I'I'H INVENTOR. .R/ENK JMULLER PATENTEDMAY 16 1972 3, 662,571 sum 11 0F 11' Fire. 31

INVENTOR. R/ENK J. MULLER A T TOP/V5 YS BACKGROUND OF THE INVENTION 1. Field of the Invention At the present time, great quantities of knitted fabric are being utilized in a great many fields, only one of which is clothing. Because of the increased rate at which this fabric is being used and because of the increased cost of labor and handling of the fabric, it is imperative that the fabric be made so that it can be processed as quickly and handled as little as possible.

2. Description of the Prior Art There are basically two types of knitting machines in the prior art, one of which is the cylindrical knitting machine and the other of which is the flatbed type. The cylindrical knitting machine has a plurality of needles positioned in a large circle and movable in the circle past cams which urge them into reciprocating knitting action. Thread is fed continuously to the needles and the knitted fabric is removed in a wale-wise direction in the center of the circle of needles. The removed fabric is in the form of a continuous cylinder and is rolled into a roll, which roll rotates with the needles to maintain each of the wales properly aligned with particular needles at all times.

The flatbed type of knitting machine is an elongated machine having needles fixedly positioned with cams moving thereby to urge the needles into reciprocating knitting action. A continuous length of fabric is removed from the flatbed machine in a wale-wise direction. These machines are extremely slow and are limited in the length of the courses, or the width of the knitted fabric.

In the production of almost all articles from knitted fabric, and especially clothes, the length of the wales does not need to be more than a maximum of approximately 30 inches. However, the length of courses necessary for different clothes and other uses varies with the size of article being produced. Because knitted fabrics stretch along the courses and are relatively stable in length along the wales, clothes such as T-shirts and the like are constructed with the wales extending longitudinally along the body and the courses extending around the body. Thus, it can be seen that for different sizes of clothes the courses will vary while the wales remain relatively constant or below an upper limit (generally 30 inches). Since all of the prior art knitting machines are limited to machines which produce knitted fabrics having continuous wales and limited courses, additional processing and much wasted fabric results. Further, the cylindrical knitting machine must be shut down to remove the roll of knitted fabric therefrom and considerable time is wasted in stopping and starting these machines again once the cloth is removed.

SUMMARY OF THE INVENTION This invention pertains to a knitting machine and method of knitting fabric with a predetermined constant length of wale and continuous courses with the machine defining a knitting area through which needles are continuously moved and urged into reciprocating knitting action and further having means for applying a bias to the knitted fabric in a wale-wise direction as it comes from the needles and means for removing the knitted fabric from the machine in a course-wise direction.

It is an object of the present invention to provide a new and improved knitting machine.

It is a further object of the present invention to provide an improved knitting machine which knits a continuous sheet of fabric in a course-wise direction.

It is a further object of the present invention to provide an improved knitting machine which is relatively fast and does not require periodic shut-down time to remove the knitted fabric.

It is a further object of the present invention to provide apparatus and methods for knitting a continuous sheet of fabric in a course-wise direction, which is especially adaptable for further automation.

These and other objects of this invention will become apparent to those skilled in the art upon consideration of the accompanying specification, claims and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Referring to the drawings, wherein like characters indicate like parts throughout the figures:

FIG. 1 is a view in side elevation of the improved knitting machine, portions thereof broken away and portions thereof removed;

FIG. 2 is a plan view as seen generally from the line 2-2 in FIG. 1;

FIG. 3 is an enlarged fragmentary elevational view as seen generally from the line 3-3 in FIG. 2, portions thereof broken away and shown in section;

FIG. 4 is a view in top plan as seen generally from the line 4-4 in FIG. 3;

FIG. 5 is an enlarged fragmentary elevational view as seen generally from the line 5-5 in FIG. 2, portions thereof broken away and shown in section;

FIG. 6 is a view in bottom plan of a single needle-carrying section, portions thereof broken away and shown in section;

FIG. 7 is an enlarged fragmentary elevational view as seen generally from the line 7-7 in FIG. 2, portions thereof broken away and shown in section;

FIG. 8 is an enlarged transverse cross-sectional view as seen from the line 8-8 in FIG. 3;

FIG. 9 is an enlarged transverse cross-sectional view as seen from the line 9-9 in FIG. 3;

FIG. 10 is an enlarged horizontal sectional view as seen from the line 10-10 in FIG. 3;

FIG. 11 is an enlarged end view of the single needle-carrying section illustrated in FIG. 6;

FIG. 12 is an enlarged horizontal sectional view illustrating the pivotal connection of two adjacent needle-carrying sections as seen generally from the irregular line 12-12 in FIG. 1 1, portions thereof broken away;

FIG. 13 is an enlarged fragmentary elevational view as seen generally from the line 13-13 in FIG. 4;

FIG. 14 is an elevational view of a single needle-carrying section as seen generally from the line 14-14 in FIG. 11, portions thereof broken away;

FIG. 15 is an elevational view of a cam section utilized in cooperation with the needle-carrying sections;

FIG. 16 is a view in bottom plan of the cam section illustrated in FIG. 15;

FIG. 17 is an enlarged fragmentary view in top plan of one end of the structure illustrated in FIG. 2', portions thereof broken away and shown in section;

FIG. 18 is a sectional view as seen from the line 18-18 in FIG. 17, portions thereof removed;

FIG. 19 is an enlarged detailed sectional view as seen from the line 19-19 in FIG. 18;

FIG. 20 is a view in bottom plan of the structure illustrated in FIG. 19, portions thereof broken away;

FIG. 21 is an enlarged sectional view as seen from the line 21-21 in FIG. 17;

FIG. 22 is an enlarged fragmentary view as seen generally from the line 22-22 in FIG. 2 illustrating a fabric take-down mechanism, portions thereof broken away;

FIG. 23 is an enlarged sectional view as seen from the line 23-23 in FIG. 22, portions thereof broken away;

FIG. 24 is an enlarged fragmentary view in top plan as seen generally from the line 24-24 in FIG. 22;

FIG. 25 is an enlarged detailed view in top plan of a portion of the take-down mechanism illustrated in FIG. 22, portions thereof broken away;

FIG. 26 is a diagrammatic view of the drive mechanism for the present knitting machine;

FIGS. 27-30 are enlarged views illustrating the operation of the take-down mechanism of FIG. 22; and

FIG. 31 is a diagrammatic view of a portion of an example of a knitted fabric which may be produced by the present knitting machine.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the figures the numeral 35 generally designates a knitting machine and the numeral 36 designates a freestanding creel associated therewith. The knitting machine 35 includes a first track generally designated 37 defining a first knitting area X-Y, a second track generally designated 38 defining a second knitting area X'Y, and first and second transport wheels generally designated 39 and 40, respectively, which are positioned at opposite ends of the spaced apart tracks 37 and 38 to define a generally oval shaped path of travel for a plurality of needle-carrying sections 41, each of which is substantially similar and all of which are pivotally attached together to form a continuous chain. Take-down mechanism, generally designated 42 and illustrated in detail in FIGS. 22-25, is associated with each of the knitting areas defined by the tracks 37 and 38. However, for simplicity and ease in understanding the drawings the take-down mechanism has been shown in phantom in FIG. 1 and eliminated from FIG. 2.

1n the present embodiment of the overall apparatus, the knitting areas X-Y and X-Y' are approximately 1,000 inches long and each have 1,000 threads supplied thereto from the creel 36. The overall length of the knitting machine 35 is approximately l feet and the diameter of each of the transport wheels 39 and 40 is approximately 16 feet. Each of the needlecarrying sections 41 is approximately 4 feet long and mounts 22 needles per inch. The needle-carrying sections 41 travel in the oval path at a rate of approximately 173 feet per minute in the knitting areas and 173.9 feet per minute around the transport wheels 39 and 40. The ends of the knitting areas Y and Y define castoff stations from which a continuous sheet of knitted fabric is removed heaving a wale length of approximately 30 inches and a continuous length in the course-wise direction. it should be understood however that the above dimensions are simply for exemplary purposes and many alterations or modifications in the size, speed, or other characteristics of the apparatus may be devised by those skilled in the art. Further, since the specific means of mounting the apparatus do not form a part of this invention and because the mounting will vary considerably with different sizes of machines and situations, no specific description of the mounting means will be included in this disclosure.

Referring to FIGS. 5-14, specific details of needle-carrying sections 41 can be seen. Each of the needle-carrying sections 41 includes a base formed of a solid, elongated block 45 having a generally rectangular shaped cross section. The bottom surface of the block 45 is flat and the opposed longitudinal sides have plates 46 fixedly attached thereto, by some means such as screws or the like, which plates 46 have outwardly projecting guides 47 attached thereto. The guides 47 have a generally triangularly shaped cross section and are designed to slide smoothly in grooves formed in the tracks 37 and 38, as will be described presently. The upper surface of the block 45 has an upwardly projecting ridge 48 formed integrally therewith and extending longitudinally therealong at approximately the transverse midpoint of the block 45. An elongated plate 49 is positioned in upstanding relationship in abutting engagement with one vertical side of the ridge 48. The plate 49 has integrally formed therein a plurality of parallel outwardly directed vanes 50 extending vertically from the upper surface of the ridge 48 to approximately the upper end of the plate 49 and the vanes 50 are spaced apart a distance slightly greater than the width of a knitting needle 51. The needles 51 utilized in the present embodiment of the knitting machine 35 are a typical commercially available latch needle having a pair of transversely outwardly extending, spaced apart butts 52 formed as an integral part thereof. When the needles 51 are positioned between the vanes 50 the respective widths are such that the butts 52 extend outwardly beyond the vanes 50 and the ridge 48 operates as a lower stop.

A pair of small blocks 53 are formed at the outermost edges of a plurality of vanes 50 as an integral part thereof. The blocks 53 have transverse openings therethrough and an elongated rod 54 is engaged through the openings and affixed in the blocks 53 by means of set screws or the like. The rod 54 extends the length of the section 41 and maintains the needles 51 slidably positioned between the vanes 50. The outermost vane 50 on each end of the section 41 is one-half as wide as the remaining vanes and is adapted to mate with an outermost vane 50 on an adjacent section 41 to form a single full-size vane 50. Thus, when adjacent sections 41 are in end-to-end, tight abutting engagement a continuous row of needles and vanes is formed.

An elongated solid plate 60, which is substantially thicker than the plate 49, is positioned on the upper surface of the block 45 in parallel abutting engagement with the plate 49. The upper surfaces of the plates 49 and form a downwardly inclined ramp along which the knitted fabric is free to fall as it is produced by the needles 51. The plate 60 is fixedly attached to the plate 49 by means of a plurality of bolts or the like so that the block 45, plate 49 and plate 60 form a rigid needlecarrying section 41. A generally rectangularly shaped opening 61 is formed through the block 45 from the bottom surface thereof to the top surface and a somewhat larger opening 62 is formed in communication with the opening 61 by providing a generally rectangularly shaped depression in the upright side of the plate 60 adjacent the plate 49. An elongated bearing surface 63 having a groove formed therein and extending approximately the length thereof, is positioned along the upper horizontal surface of the opening 62. A block 64, having a tongue extending along the upper edge thereof and slidably engaged in the groove in the bearing surface 63, is constructed somewhat shorter than the opening 62 to provide for limited longitudinal movement thereof. A lower bearing surface 65 having a groove extending longitudinally therealong and mating with a tongue in the lower edge of the block 64, is fixedly attached to the plate 60 across the bottom of the opening 62. The bearing surface 65 has a generally centrally located opening therein which communicates with the opening 61 in the block 45. A pair of elongated rods 66 extend horizontally through the plate 60 from the right end thereof to the opening 62 and one end of each of the rods 66 is threadedly engaged in an end of the block 64 while the other end extends beyond the end of the plate 60 and is pivotally aflixed to the plate 60 in the adjacent needle-carrying section 41. Thus, horizontal or longitudinal movement of the block 64 in the opening 62 provides relative movements between the adjacent needle carrying blocks 41. 1

A pair of compression spring assemblies 67 are positioned between the inner end of the opening 62 and the adjacent end of the block 64 so as to provide a bias on the block 64 tending to force it toward the opposite end of the opening 62. The bias on the block 64 is in a direction to urge the adjacent sections 41 apart. A central portion of the block 64 has a generally rectangular depression 68 on either side thereof and an L- shaped opening 69 therethrough. The L-shaped opening 69 is oriented with one leg extending generally downwardly and the other leg extending horizontally toward the rods 66. An elongated arm 70 has a slot formed adjacent one end and a roller 71 pivotally mounted therein. The opposite end of the arm 70 is bifurcated so that one branch thereof extends on each side of the block 64 in the depression 68. The upper end of the arm 70 is pivotally affixed between the plates 49 and 60 by means of a spindle extending through the upper horizontal leg of the -shaped opening 69. A roller is positioned between the branches of the bifurcated arm 70 and engaged in the vertical leg of the L-shaped opening 69 for vertical movements therein. The length of the arm 70 is such that the roller 71 at the lower end thereof extends through the opening 61 in the block 45 and is positioned somewhat therebelow. In operation, movement of the roller 71 upwardly to rotate the arm 70 causes the block 64 to slide against the bias of the spring assembly 67 and pulls adjacent sections 41 tightly together. Movement of the roller 71 downwardly and rotation of the arm 70 in the opposite direction causes the adjacent sections 41 to separate. Alignment pegs 72 in one end of each of the sections 41 mate with corresponding openings in the opposite ends of the adjacent sections 41 to align the sections properly.

Because the tracks 37 and 38 are similar, only the track 37 will be described in detail. Referring specifically to FIGS. 3, 8 and 9, the track 37 can be seen in side elevation and cross section, respectively. Support pedestals 80 are positioned in spaced apart relationship (approximately every 6 feet) beneath the tracks 37 and 38 to maintain them in the desired orientation. Each of the pedestals 80 has a flat upper surface 81 and an upwardly extending support member 82 along one edge of the surface 81 parallel with the track 37. An elongated member 83, having a generally rectangular shaped cross section, is fixedly attached to the upper surface of the support members 82 and extends the length of the track 37. The member 83 forms the outer edge of the track 37 and has a triangularly shaped groove formed in the inner surface thereof to receive the guides 47 of the needle-carrying sections 41 slidably engaged therein. A second elongated member 84, having a generally rectangularly shaped cross section and extending the length of the track 37, is positioned on the upper surfaces 81 of the support pedestals 80 adjacent the upwardly extending support members 82 and the upper surface of the member 84 is approximately in a plane with the upper surface of the support member 82. A third elongated member 85, having a generally rectangularly shaped cross section and extending the length of the track 37, is positioned on the upper surfaces 81 of the pedestals 80 in abutting engagement with the member 84. The member 85 extends upwardly beyond the upper surface of the member 84 so that the upper surfaces of the members 83 and 85 are approximately in a horizontal plane. A groove, having a generally triangularly shaped cross section, is formed in the vertically extending inner surface of the member 85 in opposed relationship to the groove in the member 83 for receiving in sliding engagement therein the guides 47 on the opposite side of the needle-carrying sections 41. Thus, the members 83, 84 and 85 cooperate to form or define an elongated depression having a generally rectangularly shaped cross section adapted to receive therein the block 45, plate 46 and guides 47 of the needle-carrying sections 41.

A plurality of cam supporting sections 90 are removably affixed to the upper surface of the member 85 in end-to-end abutting engagement so as to form a continuous wall the entire length of each of the knitting areas X-Y and X'-Y'. The cam supporting sections 90 are constructed and operate similar to cam supporting sections presently used on cylindrical knitting machines. Referring specifically to FIGS. and 16, a single cam supporting section 90 is illustrated in side elevation and bottom plan, respectively. The vertically oriented surface of the cam supporting section 90 which is directed toward the needle-carrying sections 41 adjacent thereto, has a plurality of parallel, vertically extending slots 91 formed therein. Each of the slots 91 has a generally T-shaped cross section and an elongated rod 92, having a similar T-shaped cross section, is slidably engaged in each of the slots 91. Two generally triangularly shaped earns 93 are affixed to each alternate rod 92 in vertically spaced relationship with the apex directed upwardly. The remaining rods 92 have earns 94 affixed thereon in spaced relationship above the uppermost cams 93, with the apex of each of the cams 94 directed downwardly. All of the cams 93 and 94 are fixedly attached to the rods 92 by means of bolts or the like and the entire assembly of cams 93 or 94 and rods 92 are vertically adjustable in the slots 91 for correct alignment thereof. The rods 92 extend slightly out of the slots 91 and engage slots in the rear surfaces of the earns 93 and 94 to align the cams 93 and 94 properly (see FIGS. 9, l0 and 11).

The cam supporting section 90 is positioned on the upper surface of the member 85 so that a portion of the lower surface thereof overlies a portion of the blocks 45 and adjacent plates 46 of the needle-carrying sections 41 and the vertically upright surface having the earns 93 and 94 affixed thereto is parallel with and spaced from the outwardly extending vanes 50 of the plate 49. The cams 93 and 94 are adjacent the vanes 50 so that the outwardly extending butts 52 of the needles 51 are engaged thereby to urge the needles 51 into reciprocating knitting action. In a manner well known to those skilled in the art, the uppermost butt 52 engages the downwardly inclined leading surface of the cam 94 to urge the needle 51 downwardly, after which the lowermost butt 52 engages the upwardly inclined leading surface of one of the lower cams 93 to urge the needle 51 upwardly. Two sets of lower earns 93 are provided so that different needles 5] having lower butts 52 in different positions can be utilized. In this manner different types of knitting actions can be performed. It should be understood that the earns 93 and 94 are positioned to produce a typical jersey knit fabric, as illustrated in detail in FIG. 31. As is well known in the art, many other types of knitting actions can be produced by using different types of cams 93 and 94, altering the positions thereof, eliminating cams, etc.

A plurality of generally U-shaped thread holders 95 are affixed to the upper surfaces of the cam supporting sections 90. As the threads are removed from the various spools in the creel 36, they pass between a pair of driven rollers 96 (see FIG. 1) and through the thread holders 95 to the needles 51. The rollers 96 associated with the creel 36 provide a positive drive for the threads to greatly reduce thread breakage and other problems produced by systems wherein the thread is simply pulled from the spools. In this specific embodiment, there are 1,000 threads extending from the creel 36 to each of the knitting areas X-Y and X'Y and each of these 2,000 threads is engaged through a thread holder 95. Thus, as the various needle-carrying sections 41 are moved along the tracks 37 or 38 the cams 93 and 94 urge the needles 51 into reciprocating knitting actions to form a continuous sheet of knitted fabric. As each needle 51 passes through one of the knitting areas X-Y or X-Y', a complete wale approximately 30 inches long is formed in the knitted fabric. Since needles 51 are continuously passing through the knitting areas X-Y and X-Y', a continuous sheet of knitted fabric is produced at the castofi" stations Y and Y.

To drive the needle-carrying sections 41 in the tracks 37 and 38, a longitudinally extending rack-type gear 100 is formed in the bottom surface of each of the sections 41. Periodically along the tracks 37 and 38 (in this embodiment every three feet) a driving gear 101 is rotatably mounted between a pair of upright, spaced apart support members 102 by means of an axle 103, which is journalled in the support members 102 for rotation. An elongated slot is formed in the member 84 for each of the driving gears 101 and the support members 102 mount the driving gear 101 so that it meshes with the rack gears 100 formed in the lower surface of the needle-carrying sections 41. A driven sprocket 104 is coaxially affixed to the axle 103 and driven through a chain 105 by a sprocket 106. Sprocket 106 is affixed to a drive shaft 107, which extends through one of the support members 102 to mount the sprocket 106 parallel with and spaced below the sprocket 104. Each of the drive shafts 107, which drives the plurality of driving gears 101 through sprockets 106, chains 105, sprockets 104 and axles 103, is associated with a right angle drive unit 108.

Referring to FIG. 26, a main drive unit 110, which in this embodiment is an electric motor, drives a pair of oppositely extending shafts 111 and 111 through a speed changer 112. Right angle drive units 113 and 113' are operatively attached to the outermost ends of each of the shafts 111 and 111 and output shafts thereof each extend vertically upwardly to a pair of speed changers 114 and 114'. The main drive unit 110, speed changer 112, shafts 111 and 111', and right angle drive units 113 and 113' will be located on a supporting structure, such as a floor or the like, and the speed changers 114 and 114' and the remainder of the drive apparatus attached to the speed changers 114 and 114' are located thereabove (see for example FIG. 23). One output shaft from each of the speed changers 114 and 114 is connected to the various right angle drive units 108 and 108', previously described. Each of the drive units 108 is operatively linked through a common shaft to the previous drive unit and the final drive shaft extending from the last drive unit 108 has a right angle drive unit 117 attached thereto with an output shaft extending vertically downwardly therefrom. The output shaft from the right angle drive unit 117 has a speed changer 116 afi'ixed thereto, which is utilized to drive the take-down mechanism to be described presently. The drive units 108' are similarly linked together with a final drive shaft connected to a drive assembly 115 which operates a set of rollers, not shown, similar to rollers 96 for the creel 36. A second drive shaft from the drive unit 113 is connected to a second drive assembly 115, which drives the rollers 96 for the creel 36. A second shaft from the speed changer 114 is connected to a right angle drive unit 117' and an output shaft from the unit 117 extends vertically downwardly to a speed changer 116', which drives the takedown mechanism, to be described presently. A pair of drive motors 120, which in this embodiment are electric motors, are operatively connected to speed changers 121, which are in turn connected to right angle drive units 122. Referring specifically to FIGS. 18 and 26, the output shaft of each of the right angle drive units 122 has a drive gear 123 attached thereto so as to mesh with driven gears 124. The driven gears 124 are operatively connected to rotate the transport wheels 39 and 40 as will be described presently. It should be understood that the electric motor and mechanical linkage system described above is utilized for exemplary purposes and many other driving systems, such as fluid drive, might be utilized by those skilled in the art.

Since both of the transport wheels 39 and 40 are similar, only the transport wheel 39 will be described in detail. Referring specifically to FIGS. 17 through 21, the transport wheel 39 includes an upright, fixedly mounted rigid post 125, having a plurality of outwardly radiating spokes 126 affixed to the upper end thereof, and a sleeve 127 coaxially mounted around the post 125 for rotation relative thereto, having a plurality of spokes 128 radiating outwardly from the upper end thereof and spaced slightly below the spokes 126. The gear 124 is affixed to the sleeve 127 adjacent the lower end thereof and, upon rotation of the gear 124 through rotation of the gear 123, produces rotation of the sleeve 127 and outwardly radiating spokes 128. The spokes 126 have a first cam acting ring 130 affixed to the outer ends thereof coaxial with the post 125 and a second cam acting ring 131 affixed to the underside of the spokes 126 in radially inwardly spaced relationship to the cam acting ring 130 and coaxially therewith. Each of the cam acting rings I and 131 have continuous downwardly opening grooves formed therein which vary in radial distance from the post 125 to provide functions which will become apparent presently. Each of the spokes 128 has an elongated sleeve 135 slidably engaged over the end thereof for relative longitudinal movements therebetween. An upwardly projecting finger 136 is affixed to each of the sleeves 135 so as to be slidably engaged in the downwardly opening groove in the cam acting ring 131. Thus, rotation of the spokes 128 relative to the spokes 126 causes the fingers 136 associated with each of the spokes 128 to travel in the groove of the cam acting ring 131 and produce radial or relative longitudinal movements of the sleeve 135.

An elongated arm 140 is pivotally affixed to the outermost ends of each of the sleeves 135 so as to extend transversely outwardly approximately equal amounts in opposite directions. Each arm 140 is pivotally mounted in an approximately horizontal plane by means of a spindle 141 extending through the sleeve 135 generally vertically. An elongated link 142 is fixedly attached to the spindle 141 for rotation therewith. The link 142 extends generally inwardly along the sleeve 135 and a second elongated link 143 is pivotally affixed to the innermost end of the first link 142. Longitudinally extending slots 144 are formed in the links 142 at the pivotal connection thereof to allow for relative longitudinal movements therebetween. The elongated link 143 extends generally inwardly along the sleeve 135 to a pivot point 145 affixed to one side of the sleeve 135. A crank arm 146 is fixedly attached to the link 143 at the pivot point 145 and extends outwardly therefrom at approximately The crank arm 146 has a finger 147 extending vertically upwardly from the outermost ends thereof and engaged in the groove of the cam-acting ring 130. Referring to FIG. 20, as the radius of the groove in the cam acting ring decreases the crank arm 146 pivots in a counterclockwise direction about the pivot point 145. The pivotal connection of the links 142 and 143 is pivoted downwardly (see FIG. 20) by the movement of the crank arm 146 and the arm 140 is rotated in a clockwise direction. When the radius of the groove in the cam-acting ring 130 increases the am 140 is pivoted in a counterclockwise direction through similar but opposite movements.

The radially outermost tip of each of the sleeves extends somewhat beyond the spindle 141 and has an upwardly directed flat surface 150 designed to receive a needle-carrying section 41 thereon. Each end of the arm has an outwardly projecting flat rectangularly shaped finger 151 adapted to be inserted within openings 152 (see FIG. 5) adjacent each end of each of the needle carrying sections 41. Upwardly projecting stops 153 are provided with each of the fingers 151 and serve to limit the extent to which the fingers 151 can be inserted into the openings 152. Referring specifically to FIGS. 17, 18 and 21, needle-carrying sections 41 are illustrated in engagement with arms 140.

Referring specifically to FIG. 17, as the transport wheel 39 rotates the spokes 128 rotate relative to the spokes 126 and the fingers 136 and 147 associated with each of the spokes 128 travel in the cam acting rings 131 and 130, respectively, to produce, desired radial movements of the sleeves 135 and pivotal rotation of the arms 140. In FIG. 17, the transport wheel 39 is rotating in a counterclockwise direction and as a specific spoke 128 approaches the lower track 37, the cam acting ring 130 and finger 147 rotate the arm 140 into a position parallel with the needle-carrying sections 41 egressing from the end of the track 37, as illustrated at 160. When the arm 140 and needle-carrying section 41 are parallel and the section has substantially left the track 37, the cam acting ring 131 and finger 136 cause the sleevel35 to move radially outwardly so that the flat surface and fingers 151 engage the needle-carrying section 41 and support it for further movements. At the point where the cam acting ring 131 and finger 136 cause radial outward movements of the sleeve 135, the cam acting ring 130 must be constructed so that the finger 147 does not produce rotation of the arm 140 but maintains the arm 140 parallel to the needle-carrying section 41.

The spokes I28 and arm 140 carry the needle-carrying section 41 around the periphery of the transport wheel 39 to the track 38 at the upper part of FIG. 17. As the needle-carrying section approaches the entrance to the track 38, the am 140 is again rotated to position the needle-carrying section parallel.

with the track 38 and the sleeve 135 is positioned radially so that the needle-carrying section 41 is aligned and parallel with the track 38, as at 161. Once the needle-carrying section is properly started into the track 38, the sleeve 135 and arm 140 are retracted sufficiently to pass the track 38 and continue rotation. Thus, the transport wheels 39 continually transport needle-carrying sections 41 from one end of the track 37, to the adjacent end of the track 38 and, in a like manner, the transport wheel 40 continually carries needle sections 41 from the end of the track 38 to the end of the track 37.

As the needle-carrying sections 41 approach the end of the track 37, the roller 71 (see FIG. 5) is free to move downwardly so that the spring assemblies 67 force the block 64 to the right in the opening 62 and separate each egressing needle-carrying section 41 from the adjacent section 41. This separation of the adjacent sections 41 is necessary to provide the relative rotation between adjacent needle-carrying sections 41 described in conjunction with the transport wheels 39 and 40. The member 84 of the tracks 37 and 38 is sloped downwardly prior to the inlet and outlet ends of each of the tracks 37 and 38 (as can be seen in FIGS. and 7) to allow the roller 71 to drop or rise gradually and separate or join adjacent needle-carrying sections 41 after or during the time that the sections 41 are engaged in one of the tracks 37 or 38. Further, because the needle-carrying sections are separating as they leave the track 37 and are being joined as they enter the track 38, referring to transport wheel 39, and the sections 41 are separating as they leave track 38 and being joined as they enter track 37, referring to transport wheel 40, the transport wheels 39 and 40 must travel slightly faster (in this embodiment nine-tenths of a foot per minute) than the needlecarrying sections 41 travel when they are engaged in the tracks 37 and 38. Because the needle-carrying sections 41 are not immediately joined to adjacent needle-carrying sections 41 upon entering the tracks 37 and 38, knitting action does not begin immediately and, thus, the knitting areas X-Y and X'Y' are somewhat shorter than the tracks 37 and 38, respectively. While cam supporting sections 90 may be present in areas of tracks 37, 38 outside of knitting areas X-Y and X'Y, the associated earns 93 and 94 are only present throughout the knitting areas X-Y and X'Y' and the knitting needles 51 are only urged into reciprocating knitting action as they travel through the knitting areas X-Y and X'Y. It should be understood that the knitting machine 35 might be constructed in a variety of embodiments and the present oval embodiment is believed to be the most practical for size and operation thereof. However, much of the apparatus is included because of the oval embodiment and might be eliminated or altered by those skilled in the art if a different embodiment of knitting machine 35 is devised.

As the knitting needles 51 are urged into reciprocating knitting action throughout the knitting areas X-Y and X'- the knitted fabric gradually grows in width from a single loop at the beginning X or X of the knitting area X-Y and X'Y' to a sheet of knitted fabric approximately 30 inches wide at the cast-off stations Y and Y. Some form of mechanism must be utilized to continuously remove or bias the knitting fabric from the needles 51 to insure proper knitting action. While many forms of apparatus for providing this function may be devised, the take-down mechanism 42, illustrated in FIGS. 22 through 25 and operatively illustrated in FIGS. 27 through 30, is utilized for exemplary purposes in the present embodiment of the knitting machine 35, in conjunction with each of the knitting areas X-Y and X'Y. Since the two take-down mechanisms 42 are similar, only one of them will be described in detail.

Referring specifically to FIG. 22, a first sprocket 170 is affixed to the mounting structure for the knitting machine 35 generally adjacent the beginning of one of the tracks 37 or 38, with the upper periphery thereof slightly above the knitting machine 35. In this embodiment, to coincide with the exemplary dimensions previously given, the sprocket 170 is approximately 30 inches in diameter. A second similar sprocket 171 is affixed to the mounting structure at approximately the other end of the track 37 or 38 and approximately the desired width of the sheet of knitted fabric (in this embodiment 30 inches) below the first sprocket 170. A link-type chain 172 is engaged over the sprockets 170 and 171 for continuous rotation therearound. The sprocket 171 has a smaller sprocket 173 affixed to the axle thereof and driven through a chain 174 by a sprocket 175 affixed to the drive shaft of the speed changer unit 1 16, previously described. The speed of the sprockets 170 and 171 is such that the chain 172 transverses the knitting area X-Y or X'Y in approximately the same time as the needle-carrying sections 41. Because the take-down mechanism 42 can be attached to the knitting machine 35 in a variety of configurations and because any specific configuration will depend upon the mounting structure of the knitting machine 35, the specific apparatus for mounting the take-down mechanism 42 will not be described in detail.

A plurality of hook-carrying sections 180 are fixedly attached to the chain 172 in end-to-end relationship throughout the entire length thereof. Each hook-carrying section 180 includes a pair of spaced apart plates 181 each having an elongated arm 182 fixedly attached to the chain 172 so that the plates 181 extend transversely outwardly from the plane of the chain 172 toward the knitting machine 35. Side views of the plates 181 and arms 182 can be seen in FIGS. 27-30. First and second shafts 183 and 184 are mounted in parallel spaced apart relationship between the plates 18]. The shaft 183 is mounted the closest to the outer extremity with the shaft 184 spaced inwardly toward the chain 172. A plurality of small hooks 185 are rotatably mounted on the shaft 184 in spaced apart relationship so that the shaft 183 operates to limit the rotation thereof in one direction and the hooked ends extend generally away from the chain 172 and toward the knitting machine 35. A third shaft 186 is affixed between the plates 181 parallel with the shafts 183 and 184 and spaced therefrom slightly above and toward the chain 172. The shaft 186 has a plurality of relatively long books 187 pivotally attached thereto in spaced apart relationship. The hooked ends of the hooks 187 extend in the same direction as the hooked ends of the hooks 185. In this embodiment, the hooks 185 are utilized to hook the initial loops in the sheet of knitted fabric and it is believed that there should be at least as many hooks 185 per inch as there are initial loops. There are 22 needles per inch and initially only every other needle forms a loop (see FIG. 31) which produces 11 loops per inch and, consequently, to insure accurate take-down of the knitted fabric approximately 18 books 185 per inch are provided. Similarly, approximately 18 hooks 187 are provided per inch.

An elongated channel 190 having a generally U-shaped cross section is provided beneath the upper flight of the chain 172 between the sprockets and 171 to maintain the chain 172 in the correct orientation. Similarly a channel 191 having a generally U-shaped cross section is provided as a guide for the lower flight of the chain 172. An elongated keeper or bearing surface 192, which may be formed of a material such as that sold under the trademark TEFLON" or the like, is positioned in spaced relationship above the opening of the channel 190 by means of periodically spaced apart brackets 193 and is utilized to maintain the chain 172 and the attached hook-carrying sections in the correct orientation. Similarly a keeper or bearing surface 194 is affixed to the lower channel 191 to maintain the chain 172 therein. It should be noted that the channel 190 and keeper 192 are oriented so that the chain 172 moves downwardly from the sprocket 170 to the sprocket 171 a slightly greater distance than is normal and, just before being engaged by the sprocket 171, the chain 172 moves upwardly a short distance. The reason for this bend in the upper flight of the chain 172 will be described in conjunction with the operation of the take-down mechanism 42.

A generally semi-circular camming track 200 is mounted in radially outwardly spaced relationship to the sprocket 170 so as to lie adjacent that portion of the chain 172 engaged with the sprocket 170. The camming track 200 extends along the upper flight of the chain 172 a short distance beyond the start of the knitting areas X-Y or X'Y. Referring specifically to FIG. 23, the camming track 200 is formed with a groove 201 therein designed to receive the hooks 187 in sliding engagement. The groove 201 continues the length of the camming track 200 and at the lower portion of the sprocket 170 serves to separate the hooks 187 from the hooks 185. As the groove 201 progresses around the sprocket 170 the hooks are allowed to fall forward and rest on the shaft 183. Since the upper flight of the chain 172 begins somewhat above the knitting machine 35 the hooks 185 are free of any structure. As the upper flight of the chain 172 gradually proceeds downwardly the hooks 185 eventually come into contact with an upper flat surface on the plate 49 of the needle-carrying sections 41.

A light elongated cylindrical brush 205 is rotatably mounted directly above the needles 51 of needle-carrying sections 41 at the start of the knitting areas X-Y and X'Y so as to extend a short distance therealong. The brush 205 is driven through a pulley-belt and motor arrangement 206 (see FIG. 22). The

brush 205 is a relatively soft brush and may be constructed with spaced apart rows of tufts to insure that there is no interference with the operation of the needles 51 or the hooks 185. As seen in FIG. 24, the brush 205 is canted slightly at an angle to the track 37 or 38 and the rotation is such that the knitted material is brushed away from the needles 51 onto the upper surface of the plates 49 and 60 of the needle-carrying sections 41. Thus, as the hooks 185 approach the upper surface of the plate 49 the brush 205 pushes the first knitted loops onto the upper surface of the plate 49 so they are engaged by the hooks 185. Because there are more hooks 185 than loops, each loop will be engaged by at least one hook 185.

Throughout the time that the first knitted loopsare being engaged by the hooks 185, the camming track 200 retains the hooks 187 in a generally upwardly directed orientation, as illustrated at the upper portion of the sprockets 170 in FIG. 23 and in full lines in FIG. 27. As the chain 172 progresses along the camming track 200, the hooks 187 are gradually moved into an over-center portion, as illustrated in dotted lines in FIG. 27, and when the chain 172 has progressed along the knitting area to a point where several courses of knitted fabric are available, the camming track 200 ends and the hooks 187 drop under the force of gravity into engagement with the knitted fabric (see FIGS. 28 and 29). Because of the downward bias produced by the .chain 172 the hooks 187 eventually hook into the knitted fabric and aid the hooks 185 in pulling the fabric from the knitting needles 51.

As the castoff station Y or Y is reached the knitting action ceases and the completed sheet of continuous knitted fabric is removed from the knitting machine 35 and take-down mechanism 42. At this station the chain 172 turns upwardly slightly to relieve the downward bias on the knitted fabric. Simultaneously the hooks 185 engage a camming track 210 and the hooks 187 engage a camming track 211 spaced above the camming track 210. The camming track 210 for the hooks 185 consists of an elongated bar mounted in the path of travel of the hooks 185 so as to urge them outwardly away from the knitted fabric. The camming track 211 consists of an elongated plate-like member having a slot 212 extending partially therealong from the leading edge thereof. The slot 212 is positioned so that the hooked portion of the hook 187 extends through the slot 212 with the hook 187 remaining on the outer side of the camming track 211 and the knitted fabric passing adjacent the inner side thereof. The camming track 21 1 serves to urge the hooks 187 outwardly and the knitted fabric inwardly wherein the hooks 187 and the hooks 185 are effectively disengaged. The hooks 185 and 187 then continue around the sprocket 171 and along the lower flight of the chain 172 while the knitted fabric goes to a pin conveyor or the like and into additional operations if desired (all of which is not shown).

Thus, an improved knitting machine is disclosed wherein a continuous sheet of knitted fabric is produced having continuous courses and substantially any desired width in a Wale-wise direction. The present embodiment of the machine is constructed with a plurality of knitting needles which are moved in a continuous oval, path of travel and two knitting areas are defined by the opposed straight sides of the oval path of travel. Because of the novel construction of the present knitting machine, fabric having continuous courses is produced and the fabric is produced relatively fast compared to prior art machines (utilizing the foregoing dimensions, the machine produces two sheets of knitted fabric having a width of approximately 30 inches each at a rate of approximately 173 feet per minute).

While I have shown and described a specific embodiment of this invention, further modifications and improvements will occur to'those skilled in the art. I desire it to be understood, therefore, that this invention is not limited to the particular form shown and I intend in the appended claims to cover all modifications which do not depart from the spirit and scope of this invention.

What is claimed is:

1. A knitting machine comprising:

a. a plurality of knitting needles;

b. means movably mounting said needles;

0. means for moving said needles in a continuous predetermined path with a castofi station defined in said path;

d. means for reciprocating said needles generally transversely to said path to provide a knitting action wherein a fabric is produced having courses and wales; and

e. means for continuously removing knitted fabric at the castofi station in a course-wise direction.

2. A knitting machine as set forth in claim 1 having in addition fixedly positioned thread providing means for continuously supplying thread to said needles.

3. A knitting machine comprising:

a. a frame defining a continuous path of travel and at least one knitting area with a castoff station;

a plurality of needle-carrying sections pivotally attached together to form a continuous unit;

c. means mounting said continuous unit on said frame for movement along the path of travel;

. a plurality of knitting needles mounted in each of said sections for movement transverse to the path of travel;

e. cam means fixedly attached to said frame adjacent said path of travel for engaging each of said needles during movement of said unit in said path of travel and urging said needles into a predetermined reciprocating sequential knitting action wherein a fabric having courses and wales is knitted with the courses, extending generally parallel with the path of travel;

f. means mounted on said frame in engagement with said unit for continuously moving said unit along said path of travel;

g. thread providing means fixedly positioned relative to said frame and supplying thread to said needles;

h. means for engaging the knitted fabric and providing a continuous bias thereon in the direction of the wales throughout at least a portion of the knitting area; and

i. means for continuously removing the knitted fabn'c at the castoff station in a course-wise direction.

4. A knitting machine as set forth in claim 3 wherein the frame is constructed to define a generally oval path having two opposed, generally parallel sides.

5. A knitting machine as set forth in claim 4 wherein each of the opposed sides defines a knitting area each having a cast-off station at opposite ends.

6. A knitting machine as set forth in claim 4 wherein the pivotally attached needle-carrying sections include means attaching adjacent sections for limited separating movements to allow said sections to be transported along arcuate portions of the oval path.

7. A knitting machine as set forth in claim 6 wherein the attaching means includes cam operated lever means for separating adjacent sections sufficiently to transverse arcuate portions of the path and joining adjacent sections in a continuous unit as the sections leave the arcuate portions of the path and enter straight portions.

8. A knitting machine as set forth in claim 4 wherein the frame includes two track means defining the two parallel sides of the oval and two wheels each constructed to transport the needle sections from one track means along an arcuate portion of the continuous path of travel to the other track means.

9. A knitting machine as set forth in claim 3 wherein the means for engaging the knitted fabric and providing a continuous bias includes a plurality of movably mounted hooks positioned to engage the fabric and move generally longitudinally along the knitting area with the knitting needles, said hooks further being mounted for moving generally transversely away from the path of travel of said knitting needles as the knitting of fabric progresses.

10. A knitting machine as set forth in claim 9 wherein the movably mounted hooks are afiixed to sections pivotally affixed together in a continuous unit and mounted to follow a continuous path at least a portion of which unit is relatively straight and approximately the same length as the knitting area.

11. A knitting machine as set forth in claim 3 wherein the cam means are located only along the knitting area and the thread providing means supply thread to the needles only along the knitting area for providing a continuous knitting ac tion only along the knitting area and stopping the knitting action at the castofi station.

12. A method of knitting a fabric with the longitudinal axis extending in a course-wise direction comprising the steps of:

a. continuously moving a plurality of knitting needles through a predetermined knitting area and urging said needles into reciprocating knitting action while in said knitting area;

b. supplying a plurality of threads to said knitting needles along said knitting area; and

c. removing knitted fabric from the needles at the end of the knitting area in a continuous course-wise direction.

13. A method of knitting a fabric with the longitudinal axis extending in a course-wise direction comprising the steps of:

a. continuously moving a plurality of knitting needles through a predetermined knitting area and urging said needles into reciprocating knitting action while in said knitting area;

b. supplying a plurality of threads to said knitting needles at predetermined fixed points along said knitting area;

c. biasing the knitted fabric transversely of the knitting area generally away from the knitting needles in a Wale-wise direction; and

d. continuously removing knitted fabric from the knitting needles at the end of the knitting area in a course-wise direction.

14. A method of knitting a fabric with the longitudinal axis extending in a course-wise direction as set forth in claim 13 wherein the step of continuously removing the knitted fabric is further characterized by retaining the fabric in a non-rotating position about the longitudinal axis of the fabric as the fabric is removed from the knitting area. 

1. A knitting machine comprising: a. a plurality of knitting needles; b. means movably mounting said needles; c. means for moving said needles in a continuous predetermined path with a castoff station defined in said path; d. means for reciprocating said needles generally transversely to said path to provide a knitting action wherein a fabric is produced having courses and wales; and e. means for continuously removing knitted fabric at the castoff station in a course-wise direction.
 2. A knitting machine as set forth in claim 1 having in addition fixedly positioned thread providing means for continuously supplying thread to said needles.
 3. A knitting machine comprising: a. a frame defining a continuous path of travel and at least one knitting area with a castoff station; b. a plurality of needle-carrying sections pivotally attached together to form a continuous unit; c. means mounting said continuous unit on said frame for movement along the path of travel; d. a plurality of knitting needles mounted in each of said sections for movement transverse to the path of travel; e. cam means fixedly attached to said frame adjacent said path of travel for engaging each of said needles during movement of said unit in said path of travel and urging said needles into a predetermined reciprocating sequential knitting action wherein a fabric having courses and wales is knitted with the courses extending generally parallel with the path of travel; f. means mounted on said frame in engagement with said unit for continuously moving said unit along said path of travel; g. thread providing means fixedly positioned relative to said frame and supplying thread to said needles; h. means for engaging the knitted fabric and providing a continuous bias thereon in the direction of the wales throughout at least a portion of the knitting area; and i. means for continuously removing the knitted fabric at the castoff station in a course-wise direction.
 4. A knitting machine as set forth in claim 3 wherein the frame is constructed to define a generally oval path having two opposed, generally parallel sides.
 5. A knitting machine as set forth in claim 4 wherein each of the opposed sides defines a knitting area each having a cast-off station at opposite ends.
 6. A knitting machine as set forth in claim 4 wherein the pivotally attached needle-carrying sections include means attaching adjacent sections for limited separating movements to allow said sections to be transported along arcuate portions of the oval path.
 7. A knitting machine as set forth in claim 6 wherein the attaching means includes cam operated lever means for separating adjacent sections sufficiently to transverse arcuate portions of the path and joining adjacent sections in a continuous unit as the sections leave the arcuate portions of the path and enter straight portions.
 8. A knitting machine as set forth in claim 4 wherein the frame includes two track means defining the two parallel sides of the oval and two wheels each constructed to transport the needle sections from one track means along an arcuate portion of the continuous path of travel to the other track means.
 9. A knitting machine as set forth in claim 3 wherein the means for engaging the knitted fabric and providing a continuous bias includes a plurality of movably mounted hooks positioned to engage the fabric and move generally longitudinally along the knitting area with the knitting needles, said hooks further being mounted for moving generally transversely away from the path of travel of said knitting needles as the knitting of fabric progresses.
 10. A knitting machine as set forth in claim 9 wherein the movably mounted hooks are affixed to sections pivotally affixed together in a continuous unit and mounted to follow a continuous path at least a portion of which unit is relatively straight and approximately the same length as the knitting area.
 11. A knitting machine as set forth in claim 3 wherein the cam means are located only along the knitting area and the thread providing means supply thread to the needles only along the knitting area for providing a continuous knitting action only along the knitting area and stopping the knitting action at the castoff station.
 12. A method of knitting a fabric with the longitudinal axis extending in a course-wise direction comprising the steps of: a. continuously moving a plurality of knitting needles through a predetermined knitting area and urging said needles into reciprocating knitting action while in said knitting area; b. supplying a plurality of threads to said knitting needles along said knitting area; and c. removing knitted fabric from the needles at the end of the knitting area in a continuous course-wise direction.
 13. A method of knitting a fabric with the longitudinal axis extending in a course-wise direction comprising the steps of: a. continuously moving a plurality of knitting needles through a predetermined knitting area and urging said needles into reciprocating knitting action while in said knitting area; b. supplying a plurality of threads to said knitting needles at predetermined fixed points along said knitting area; c. biasing the knitted fabric transversely of the knitting area generally away from the knitting needles in a wale-wise direction; and d. continuously removing knitted fabric from the knitting needles at the end of the knitting area in a course-wise direction.
 14. A method of knitting a fabric with the longitudinal axis extending in a course-wise direction as set forth in claim 13 wherein the step of continuously removing the knitted fabric is further characterized by retaining the fabric in a non-rotating position about the longitudinal axis of the fabric as the fabric is removed from the knitting area. 